Method of making floorings, roofings, and like fabrics.



F. c. OVERBURY. METHOD 0F MAKING FLOORINGS, ROOFINGS, AND LIKE FABRICS.

APPLICATION FILED IULYZ, 1912. 1,182,41@ Patented May 9, 1916.

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UNITED STATES PATENT oFFIcE.

FREDERICK C. OVERBUBY, 0F NEW YORK, N'..Y., ASSIGNOB T0 FLINTKOTE MANUFAC- 'TURING COMPANY, 0F LUTHER-FORD,

JERSEY.

JERSEY, A. CORPORATIQN 0F NEW METHOD 0F MAKING' FLOOBINGS,BOOFINGS, LIKE FABRICS.

Specification of Letters Patent.

Patented May 9, 1916.

Application filed July 2, 1912. ASerial No. 707,179.

coverings in which a suitable foundation,

such as fabric, felt or paper, is impregnated or saturated with a waterproofing compound and is coated with a water or weather-resist-- ing coating or facing. Various compounds or mixtures have been practicallyemployed in the impregnation or saturation of the foundation, such, for instance, as asphaltum, pitch or other hydrocarbon materials, the outer facing or coating` usuallyv comprising a relatively harder asphaltum `or pitch so that it will not be melted by the heat of the sun. Such roofings, floorings or like coverings are also colored by the addition of a suitable pigment to the mixture or substance which forms the outer layer or facmg.

In the practical manufacture of such articles, a sheet or foundation material is carried through a vat containing the impregnating mixture, and, after the surplus mixture has been removed by pressure rolls, the sheet is passed betweenrollers or scra ers which apply to one or both faces thereo the proper amount of the facing or coating substance or mixture. The coatings or facings of prepared roongs or loorings thus manufactured are always more or less uneven, rough or corrugated, and have a shiny appearance, particularly those which 4are colored other than black. f

The object of the present invention is to provide a method of making rooings or iloorings in which such characteristic machine marks do not appear on the surface of the goodsv and inl which the surface is dully or flat, that is, Without the 'shiny effeet that is ordinarily produced.

The invention has further for itsv object the ornamentation of such materials'by printing thereon various designs.

I accomplishl these objects by pressing temporary layers of suitable material, such as paper, metal or the like, upon the outer facing or coating while it is still lastic, so

that, when said layer is remove the sur face of the facing is smooth with what may be termed a dull or fiat finish. The temporary layer may be removed immediately, or else it may be allowed toyremain on the goods while they are in storage or in transit and be removed when the goods'are to be removed. v

On the accompanying drawing, Figure 1 illustrates conventionally instrumentahties which may be employed in carrying out my process. Fig. 2 illustrates another instrumentality which may be utilized in removing` the temporary layer. Fig. 3 shows the scraper employed in the instrumentality shown in Fig. 2. Fig. 4-illustrates a temporary layer consisting of an endless band. n

Referring to the drawings,-a sheet of felt, paper, fabric or other suitable mate-4 rial to form the base or foundation of the flooring or roofing, is indicated at a., and is drawn from a roll w through a`vat 5 which contains a molten hydrocarbon material, such as pitch, asphalt or a combination of the-same or of oils, resins or other substances which will impregnate the sheet 4and make it waterproof. Any substance or substances for this'purpose, whichare now well known to those skilled in thek art, may be employed. After leaving the vat, the impregnated sheet -a may be passed through squeeze rolls 6 which remove the surplus impregnating material.

As previously stated, the impregnatedV sheet may be coated or faced on either one or both sides. As shown, the coating material is applied tobut one side of the sheet and is contained in a tank 7 from which it Y Hows through a pipe 8 to a slotted or perforated delivery pipe 9, whence it flows upon v regulate the thlckness of the skin or surface the sheet which is carried over a tray or coating. The sheet then passes through pressure rolls 12 12 and thence betweeri'-cooling drums 13. vb indicates the temporary.' y layer which is delivered from a roll b andpasses with the coated sheet between the pressure rolls 12 around the cooling drum 13. The sheet, having the temporary layer,

'is then passed between rolls I4 14 and the- ,a fiat or dull finish.'

temporary layer is then strippedA from the face of the coated material and 1s 'wound upon a roll 15, the vsheet a being wound upon a'l roll 16. The skin coating or facing of the sheet may consist of any of the usual pitch like materials, such as asphaltum,

pitch or the like, to render the sheet waterproof or weatherproof and" is preferably applied ina hot plastic state, so that, when the temporary layer is pressed upon 1t, 1t

adheres thereto until it is removed, and,` as

the sheets with the-temporary facings pass between the rolls 12 12, 13 13, the said temporary layer is pressed with suiiicient force, fupon the coa-ting of facing material to flatten and smooth it and prevent the formation 'of any roughness, unevenness or corrugation upon the' surface thereof. When the temporary layer is then removed, the skin coating Yor facing is perfectly smooth with I preferably employ as the `.temporary llayer a' sheet of sized or parained paper or other material which will not adhere' so tenaciously-to the skin coating as to prevent iooring by passing the latter` through a.

tank 17 containing cooled Water to soften the temporary layer so that it may be removed by a scraper 117, as indicated in Figs.

'2 and 3, the scraper consisting of a' roll for instance having oppositely extending helical blades 'of any suitable material such as,

bristles', felt, leather, compressed' ber on the like.

stick to the surface of the coated fabric. If desirable, .the temporary layer may remain updn the saturated and coated fabric and be,

rolled up with it and removed when the goods are ready to beused. Instead of employing a sheet of paper, asindicated in Fig. 1, I may employ an endless band as a temporary layerfas indicated in Fig. 4. The band in this instance may be sized or par- Y 'afflned paper, or it may consist of a metallicy belt as 'indicated at 18.u This band passes with the impregnated and coated fabric between the pressurerolls 12 12, 'the cooling drums 13 13, and the rolls 14 14:, all of which correspond to those represented by the same numerals'in Fig. 1.

I have -found that, by the method which I have described, the face of *the xprepared fabric may be ornamented by the employment of a colored or printed vsheet of paper,

coloring matter being deposited and. left on' the vfacing material. While I preferably employ. a facing material which is solved byheat, vnevertheless. I

These instrumentalities may be 'utilized where the paperhas a tendency to 'would not` consider a departure from the" invention if the facing material vwere applied cold and a suitable solvent employed for rendering it soft and plastic. If desired, the temporary layer may be oiled prior t0 its contact with the soft and plastic skin coating or o'thenmeans may be utilized to prevent its sticking permanently to the ing or coatingdmaterial.

I appreciate 'that 4the invention may be practised in a variety of ways Land that various instrumentalities may be employed in carrying out the invention. So far as I am aware, however, I am the lirst to have provided a method of making flexible prepared roofing or flooring in Which the Ysurface or skin coating is smoothed by the employment of a temporary layer pressed thereon While the facing or coating is in a soft or plastic state. i

Having thus` explained the natureof my said invention and described a way of constructing and using the same, although facwithout attempting'lto set forth all of the forms in which it may be made or all of fthe modes of its use, what I claim `is:

1. The 'here'in described method of mdk! ing iexible roofing, flooring orithe like, which consists in impregnatin-gga sheet of' fibrous material with a. waterproofing compound, applying to said impregnated sheet a. plaster coating of pitch, asphalt or equiva lent weatherproof waterproof f compound, pressing upon said coating while it is plast'c a temporary removable layer of suitable m terial to form a smooth surface upon the said coatingfand permitting said coatingto set and harden. f

2.'I`he hereindescribed method of making flexible roofing, iiooring or the like, which comprises applying to a sheet lof waterproofed fibrous material a plastic coat.- 'ing of pitch or asphalt, pressingupon said -coating while it is plastic a removable tem- .poraryl'ayer of suitable material, permitting said coating to set and harden, and then removing said temporary layer, leaving said coating sm'ooth and flat.,.

3.-The l'hereindescribed method of mak- L ing iiexible roong, i iooring or the like, which comprises applying to a sheet of waterproofed fibrousmaterial a plastic coating ofp-itch or asphalt, pressing uponsaid coating while it is plastic a removable temporary layer of suitable material, the surface of which is printed. or colored, thereby to transfer the color to the said coating, and

then removing said; temporary layer leav? smooth land printed orl ing said coating colored.

.4. The herein described method of making weatherproof roofing, 'iiooring "or the like, which consists in ,applyingto ay suitable foundation a facing or coating of hot plasticweatherproof pitchlike material,

Lisam and, while said coating is plastic, pressing thereon a temporary removable sheet of Inaterial to ,smooth the surface of said facing or coating. chilling said coating to harden it, and then stripping said sheet therefrom.

5. The herein described method, which consists in applying a hot plastic waterproof material to a suitable foundation to form a layer 0r coating thereon, pressing upon said coating while it is plastic a sheet of suitable material to form a smooth surface thereon, cooling said coating to harden it, stripping said sheet therefrom, and coiling thel coated foundation in a marketable mass.

6. The herein described method, which consists in applying a hot plastic pitch-like i waterproof material to a suitable Waterproof foundation to form a layer or coating thereon, pressing upon said coating while it is plastic a sheet of colored or printed material, cooling said coating to cause it to harden and set, stripping the said sheet therefrom, and leaving on the surface of 'said coating the coloring or printed matter.

In testimony whereof I have affixed my signature 1n presence of two Witnesses.

FREDERICK o. ovERBURY.

Witnesses:

W. SCHAEFER, L. B. FANGER. 

